REAR DIFFERENTIAL CARRIER ASSEMBLY (for 2GR-FSE) DISASSEMBLY


  1. REMOVE REAR DIFFERENTIAL BREATHER PLUG


    1. A01FJ0D

      Remove the rear differential breather plug from the rear differential carrier cover.

  2. REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. A01FGP6

      Remove the 8 bolts.

    2. A01FEB9

      Using a brass bar and hammer, remove the rear differential carrier cover from the rear differential carrier.

      Note


      • Place the brass bar onto the corners of the rear differential carrier cover.

      • Do not damage the sealing surface of the rear differential carrier.

  3. REMOVE REAR DIFFERENTIAL CARRIER STRAIGHT PIN


    1. A01FEXA

      Remove the 2 rear differential carrier straight pins from the rear differential carrier cover.

  4. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01FENU

      Remove the bolt and rear differential breather plug oil deflector from the rear differential carrier cover.

  5. SECURE REAR DIFFERENTIAL CARRIER


    1. A01FHJTE01

      Install the rear differential carrier to an overhaul stand as shown in the illustration.

  6. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A01FFHZE01

      Set a dial indicator perpendicular to the end of the differential ring gear face.

    2. Rotate the differential ring gear and measure the runout.

      Maximum runout
      0.05 mm (0.00197 in.)

      If the runout is more than the maximum, remove the differential ring gear and check the runout of the rear differential case sub-assembly.

  7. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01FE2RE01

      While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

      Backlash
      0.08 to 0.13 mm (0.00315 to 0.00511 in.)

      If the backlash is not within the specified range, adjust the backlash or perform repairs as necessary.

  8. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01FI8Y

      Coat 3 or 4 teeth at 3 different positions on the differential ring gear with Prussian blue.

    2. Rotate the differential ring gear in both directions.

    3. Inspect the tooth contact pattern.

      A01FDE8E01
      Text in Illustration
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select an adjusting washer that will shift the drive pinion closer to the ring gear (*b, *c)
      *e Toe Contact *f Flank Contact
      *g Select an adjusting washer that will shift the drive pinion closer to the ring gear (*e, *f) - -

  9. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01FJ2A

      Place a dial indicator on the tip of a side gear tooth at a right angle. Hold the pinion gear in the rear differential case sub-assembly and check that the backlash is 0 mm (0 in.).

      If the result is not as specified, replace the rear differential case sub-assembly with a new one.

  10. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION


    1. A01FH8ZE02
      Text in Illustration
      *a 10 mm (0.394 in.)

      Using a dial indicator, measure the runout of the differential drive pinion shaft at a position 10 mm (0.394 in.) away from the end of the shaft.

      Maximum runout
      0.08 mm (0.00315 in.)

      If the runout is more than the maximum, replace the differential drive pinion and differential ring gear.

  11. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01FISYE05

      Using SST and a torque wrench, measure the starting torque of the differential drive pinion.

      SST
      09229-55010
      Differential drive pinion preload (at starting)
      1.25 to 1.65 N*m (12.75 to 16.83 kgf*cm, 11.06 to 14.60 in.*lbf)

      Tech Tips


      • The backlash between the differential drive pinion and differential ring gear should allow enough movement of the differential drive pinion to allow this measurement to be performed.

      • Make sure not to include the preload of the differential ring gear (rear differential case sub-assembly) in the measurement of the differential drive pinion preload.

  12. INSPECT TOTAL PRELOAD


    1. A01FISYE05

      Using SST and a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.

      SST
      09229-55010
      Total preload (at starting)
      for 2WD
      1.74 to 2.96 N*m (17.74 to 30.18 kgf*cm, 15.40 to 26.20 in.*lbf)
      for AWD
      1.63 to 2.67 N*m (16.62 to 27.23 kgf*cm, 14.43 to 23.63 in.*lbf)

  13. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01FI9SE01

      Using SST, remove the 2 rear differential side gear shaft oil seals.

      SST
      09308-00010

  14. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING


    1. A01FI0NE05
      Text in Illustration
      *1 Disc

      Install SST to the rear differential carrier with the 2 bolts (A).

      SST
      09571-50010

    2. Tighten SST bolt (B) until SST disc lightly touches the rear differential case bearing outer race RH on the differential ring gear tooth side.

    3. A01FEL6E01

      Install a dial indicator to the rear differential carrier.

      Tech Tips

      Set the dial indicator as shown in the illustration.

    4. Tighten SST bolt and alter the shape of the rear differential carrier to create a 0.1 mm (0.00394 in.) clearance between the rear differential case bearing outer race RH and rear differential side gear shaft snap ring.

      Note

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

      Tech Tips

      A clearance of approximately 0.1 mm (0.00394 in.) between the rear differential case bearing outer race RH and rear differential side gear shaft snap ring is sufficient for the rear differential side gear shaft snap ring to move slightly.

    5. A01FH7AE01

      Using SST, remove the rear differential side gear shaft snap ring on the differential ring gear tooth side.

      SST
      09905-00031

      Tech Tips

      For reassembly purposes, measure the thickness of the rear differential side gear shaft snap ring. Write down the result.

    6. Remove the dial indicator and loosen SST bolt.

      Note

      Do not remove SST.

    7. A01FG43E01

      Using SST and a hammer, create a clearance between the rear differential case bearing outer race LH on the back surface of the differential ring gear and the rear differential side gear shaft snap ring.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.

    8. A01FDOQE01

      Using snap ring pliers, remove the rear differential side gear shaft snap ring on the back surface of the differential ring gear.

      SST
      09905-00031

      Tech Tips

      For reassembly purposes, measure the thickness of the rear differential side gear shaft snap ring. Write down the result.

  15. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01FHZDE01

      Tighten SST bolt and push out the rear differential case bearing outer race LH on the back surface of the differential ring gear.

      SST
      09571-50010

      Note

      Do not drop the rear differential case bearing outer race LH.

      Tech Tips

      Put identification marks on the rear differential case bearing outer race and rear differential side gear shaft snap ring to show the location for installation (back side or teeth side), or keep the races and snap rings separate so that they can be distinguished.

    2. A01FI0NE02

      Remove the 2 bolts and SST.

    3. A01FFWCE01

      Raise the differential ring gear side of the rear differential case sub-assembly slightly to remove the rear differential case bearing outer race RH on the differential ring gear tooth side.

      Tech Tips

      Put identification marks on the rear differential case bearing outer race and rear differential side gear shaft snap ring to show the location for installation (back side or teeth side), or keep the races and snap rings separate so that they can be distinguished.

  16. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01FFP6

      Remove the rear differential case sub-assembly as shown in the illustration.

      Note

      Do not damage the rear differential case bearing.

  17. REMOVE REAR DRIVE PINION NUT


    1. A01FHHEE01

      Using SST and a hammer, unstake the staked part of the rear drive pinion nut.

      SST
      09930-00010

      Note


      • Be sure to use SST with the tapered surface facing the differential drive pinion.

      • Do not grind the tip of SST with a grinder, etc.

      • Completely loosen the staked part of the rear drive pinion nut when removing it.

      • Do not damage the threads of the differential drive pinion.

    2. A01FGTPE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the rear drive pinion companion flange, remove the rear drive pinion nut.

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )

  18. REMOVE REAR DRIVE PINION COMPANION FLANGE


    1. A01FHS9E02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the rear drive pinion companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060 )

      Note

      Apply grease to the threads of SST center bolt before use.

  19. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when the rear differential dust deflector is damaged.


    1. A01FEI4E01

      Using SST and a press, remove the rear differential dust deflector.

      SST
      09950-00020
      09950-60010   ( 09951-00440 )
      09950-70010   ( 09951-07100 )

      Note

      Do not drop the rear drive pinion companion flange.

  20. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01FG97E02
      Text in Illustration
      *1 Rear Differential Carrier Oil Seal

      Using SST, remove the rear differential carrier oil seal from the rear differential carrier.

      SST
      09308-00010

  21. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01FILI

      Remove the rear differential drive pinion oil slinger.

  22. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01FI1I

      Using a press, remove the differential drive pinion from the rear differential carrier.

      Note

      Do not drop the differential drive pinion.

  23. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01FF9T

      Remove the rear differential drive pinion bearing spacer from the differential drive pinion.

  24. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01FI93

      Remove the rear drive pinion front tapered roller bearing inner race from the rear differential carrier.

    2. A01FJ2RE01
      Text in Illustration
      *1 Outer Race

      Using a brass bar and hammer, remove the rear drive pinion front tapered roller bearing outer race from the rear differential carrier.

  25. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01FGALE01

      Using SST and a press, remove the rear drive pinion rear tapered roller bearing inner race from the differential drive pinion.

      SST
      09950-00020

      Tech Tips

      If either the differential drive pinion or differential ring gear is damaged, replace both as a set.

    2. A01FEP8E02
      Text in Illustration
      *1 Rear Differential Drive Pinion Plate Washer
      *2 Outer Race

      Using a brass bar and hammer, remove the rear drive pinion rear tapered roller bearing outer race from the rear differential carrier.

    3. Remove the rear differential drive pinion plate washer.

  26. REMOVE DIFFERENTIAL RING GEAR


    1. A01FIVNE05
      Text in Illustration
      *a Matchmark

      Put matchmarks on the differential ring gear and rear differential case sub-assembly.

    2. Remove the 10 ring gear set bolts.

    3. A01FFSR

      Using a plastic-faced hammer, tap on the differential ring gear to remove it from the rear differential case sub-assembly.

      Note

      Do not damage the differential ring gear.

  27. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when the runout of the differential ring gear exceeds the specified maximum value.


    1. A01FE29

      Insert the rear differential case sub-assembly from the differential ring gear tooth side to install the rear differential case sub-assembly as shown in the illustration.

      Note

      Do not damage the rear differential case bearing.

    2. A01FFDHE02
      Text in Illustration
      *a Groove

      Using SST and a hammer, install the rear differential case bearing outer race RH to the differential ring gear tooth side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      Tap in the rear differential case bearing outer race RH until half of the rear differential side gear shaft snap ring groove of the rear differential carrier can be seen.

    3. A01FFVUE04
      Text in Illustration
      *1 Disc

      Install SST to the rear differential carrier with the 2 bolts (A).

      SST
      09571-50010

    4. Tighten SST bolt (B) until SST disc lightly touches the rear differential case bearing outer race RH.

    5. A01FI2EE01

      Using SST and a hammer, install the rear differential case bearing outer race LH to the differential ring gear back surface side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      Tap in the rear differential case bearing outer race LH until it touches the rear differential case bearing inner race roller.

    6. A01FDOQE01

      Using snap ring pliers, install the rear differential side gear shaft snap ring to the rear differential carrier on the differential ring gear back surface side.

      SST
      09905-00031
    7. A01FDXOE01

      Place a dial indicator on the rear differential case sub-assembly flange surface at a right angle.

    8. Using a dial indicator, measure the rear differential case sub-assembly runout.

      Maximum runout
      0.05 mm (0.00197 in.)

      If the runout is more than the maximum, replace the rear differential case sub-assembly with a new one.

    9. A01FDOQE01

      Using snap ring pliers, remove the rear differential side gear shaft snap ring from the differential ring gear back surface side.

      SST
      09905-00031
    10. A01FIP6E01

      Tighten SST bolt to push out the rear differential case bearing outer race LH from the back surface of the differential ring gear.

      SST
      09571-50010

      Note

      Do not drop the differential side bearing outer race LH.

    11. A01FG7NE01

      Remove the 2 bolts and SST.

    12. A01FDE3

      Raise the differential ring gear side of the rear differential case sub-assembly slightly to remove the differential side bearing outer race RH on the differential ring gear tooth side.

    13. A01FJ3N

      Remove the rear differential case sub-assembly from the rear differential carrier as shown in the illustration.

      Note

      Do not damage the rear differential case bearing.

  28. REMOVE REAR DIFFERENTIAL CASE BEARING

    Tech Tips

    Perform this procedure only when replacing the rear differential case bearing or rear differential case sub-assembly.


    1. A01FEU5E05
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the rear differential case bearing inner races LH and RH from the rear differential case sub-assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00350, 09951-00480, 09952-06010 )

      Note


      • Do not deform the bearing cage if the bearing is to be reused.

      • Hook the claws of SST to the rear differential case bearing inner race.

      • Apply grease to the threads and tip of SST center bolt before use.

  29. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01FEHV

      Secure the rear differential case sub-assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Place a dial indicator on the tip of a side gear tooth at a right angle. Hold the pinion gear in the rear differential case sub-assembly and check that the backlash is 0 mm (0 in.).

      If the result is not as specified, replace the rear differential case sub-assembly with a new one.